Apparatus and method for repairing an existing spill containment manhole

ABSTRACT

An apparatus for repairing an existing spill containment manhole operably associated with an underground fuel storage tank. The apparatus includes a containment vessel for containing fuel spilled during filling of the underground fuel storage tank. A major portion of the containment vessel is adapted to be inserted into an existing spill containment manhole. Preferably, the containment vessel includes an upper annular flange that extends over and surrounds a portion of an existing cover rim of an existing spill containment manhole thereby isolating an upper portion of the containment vessel from an upper portion on the existing spill containment manhole when the containment vessel is installed. Optionally, a replacement cover is provided to replace an existing cover of the existing spill containment manhole. The replacement cover may include at least one sealing member that engages the inner surface of the at least one wall of the containment vessel when installed.

RELATED APPLICATIONS

The subject patent application is a continuation of U.S. patentapplication Ser. No. 12/662,118 filed on Mar. 31, 2010. The entirecontent of U.S. patent application Ser. No. 12/662,118 is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to spill containment manholes that areoperably associated with underground fuel storage tanks. Moreparticularly, the present invention relates to an apparatus forrepairing an existing spill containment manhole. The phrase “repairingan existing spill containment manhole” as used herein includes upgradingan existing spill containment manhole as well as servicing an existingspill containment manhole that is leaking or suspected to leak in thefuture.

BACKGROUND OF THE INVENTION

A variety of spill containment devices or manholes have been employed toprevent contamination of the surrounding environment during the processof filling underground storage tanks with hazardous liquids includingfuels like gasoline. Service stations dispensing gasoline, diesel, andother fuels commonly employ underground storage tanks for storingvarious types of fuels. The underground storage tanks typically includea riser pipe through which the fuel is dispensed from and transferred tothe underground storage tank. The riser pipe is connected to and extendsupwardly from an opening in the underground fuel storage tank.

A pipe section commonly known as a fill port or nipple is typicallyconnected to the riser pipe. A removable fill cap is usually secured tothe fill port or nipple. The fill cap is removed to fill the undergroundfuel storage tank.

Spill containment manholes or devices have been used to provide accessto the fill port of the underground fuel storage tank and preventcontamination of the surrounding environment. For example, fuel can anddoes spill when the dispensing hose from the fuel truck is connected ordisconnected to the fill port. In addition, fuel spills may occur if theunderground storage tank is overfilled. The spill containment manholesor devices were designed to trap spilling fuel to prevent contaminationof the surrounding environment. Specifically, the spill containmentmanhole or device surrounds and contains the fill port or nipple. Byproviding a containment vessel surrounding the fill port, the spillcontainment manhole or device can prevent fuel spills caused during theprocess of filing the underground fuel storage tank from contaminatingthe environment.

The spill containment manhole or device typically includes a removablecover to allow an individual to access the fill cap and fill port. Thespill containment manhole or device may have a drain operably connectedto the riser pipe to drain any fuel trapped by the spill containmentmanhole back into the underground fuel storage tank.

Over time the spill containment manhole or device deteriorates making itconsiderably more likely that a crack or other imperfection will formallowing fuel to leak into the surrounding environment that normallywould have been trapped by the spill containment manhole or device.Attempts have been made to provide a bucket or liner that can beinserted into an existing manhole to repair an existing leak orpotential leak. One such product is THE LINEBACKER™ made by JGDProducts, LLC. This product has several inherent disadvantages. First,the bucket or liner does not extend up to the ground surface. Therefore,the bucket or liner does not isolate the existing spill containmentmanhole. Rather, at least an upper portion of the existing spillcontainment manhole must be relied upon to prevent fuel from leakinginto the surrounding environment. Further, this design requires asealant be applied to the vertical wall of the bucket or liner and theadjacent portion of the existing spill containment manhole inside of thecontainment area of the existing spill containment manhole. Therefore,if the sealing material deteriorates overtime or is incorrectly appliedin the first instance, fuel can escape into the surrounding environmentthrough the defective or deteriorated seal. Another disadvantage of thisproduct is that the same removable cover is typically reused. THELINEBACKER™ bucket or liner does not provide a direct seal with theremovable cover. In other words, the removable cover does not sealdirectly to the THE LINEBACKER™ bucket or liner. Again the bucket orliner fails to isolate the existing spill containment manhole. Rather,at least an upper portion of the existing spill containment manhole mustbe relied upon to prevent fuel from leaking into the surroundingenvironment. Another disadvantage with this product is that it uses abulky connector for connecting the bucket or liner in a fluid tightmanner to the fill port and/or corresponding coupling or fitting. Thisis undesirable as there is limited space. A further disadvantage of thisproduct is that it does not include a vehicle for draining fuel backinto the underground fuel storage tank from the bucket or liner.

OBJECTS AND SUMMARY OF THE INVENTION

An object of a preferred embodiment of the present invention is toprovide a novel and unobvious apparatus for repairing an existing spillcontainment manhole or device.

Another object of a preferred embodiment of the present invention is toprovide a kit for repairing an existing spill containment manholewithout breaking the concrete or asphalt layers retaining an existingcover rim.

A further object of a preferred embodiment of the present invention isto provide a kit for repairing an existing spill containment manhole ordevice that isolates the existing spill containment manhole or device.

Still a further object of a preferred embodiment of the presentinvention is to provide a kit for repairing an existing spillcontainment manhole or device where the kit includes a replacement coverand a containment vessel where the replacement cover is sealed directlyto the containment vessel when installed.

Yet still another object of a preferred embodiment of the presentinvention is to provide a containment vessel that can be readilyinserted into an existing spill containment manhole where no seal isrequired between a vertical wall of the containment vessel and theadjacent area of the existing spill containment manhole.

Yet another object of a preferred embodiment of the present invention isto provide a containment vessel that is designed to extend over an innerportion of an existing cover rim to eliminate the need for a sealantbetween a vertical wall of the containment vessel and the adjacent areaof the existing spill containment manhole.

Still a further object of a preferred embodiment of the presentinvention is to provide a containment vessel that includes a compactseal assembly that provides a fluid tight seal between the bottom of thecontainment vessel and the fill port.

Another object of a preferred embodiment of the present invention is toprovide a kit for repairing an existing spill containment manhole ordevice where the kit includes a containment vessel and means fordraining the containment vessel.

It must be understood that no one embodiment of the present inventionneed include all of the aforementioned objects of the present invention.Rather, a given embodiment may include one or none of the aforementionedobjects. Accordingly, these objects are not to be used to limit thescope of the claims of the present invention.

In summary, one preferred embodiment of the present invention isdirected to a kit for repairing an existing spill containment manholeoperably associated with an underground fuel storage tank. The kitincludes a containment vessel for containing fuel spilled during fillingof the underground fuel storage tank. A major portion of the containmentvessel is adapted to be inserted into an existing spill containmentmanhole. The containment vessel includes at least one wall thatsurrounds an existing pipe section operably associated with theunderground fuel storage tank when the containment vessel is installed.The at least one wall has an inner surface and an outer surface. The kitfurther includes a replacement cover to replace an existing cover of theexisting spill containment manhole. The replacement cover has at leastone sealing member that engages the inner surface of the at least onewall of the containment vessel when installed.

Another embodiment of the present invention is directed to a kit forrepairing an existing spill containment manhole operably associated withan underground fuel storage tank. The kit includes a containment vesselfor containing fuel spilled during filling of the underground fuelstorage tank. A major portion of the containment vessel is adapted to beinserted into an existing spill containment manhole. The containmentvessel includes at least one wall that surrounds an existing pipesection operably associated with the underground fuel storage tank whenthe containment vessel is installed. The at least one wall has an innersurface and an outer surface. The containment vessel further includes anannular flange disposed adjacent an upper portion of the at least onewall. The annular flange extends over and surrounds a portion of anexisting cover rim of an existing spill containment manhole therebyisolating an upper portion of the containment vessel from an upperportion on the existing spill containment manhole when the containmentvessel is installed.

A further embodiment of the present invention is directed to a kit forrepairing an existing spill containment manhole operably associated withan underground fuel storage tank. The kit includes a containment vesselfor containing fuel spilled during filling of the underground fuelstorage tank. A major portion of the containment vessel is adapted to beinserted into an existing spill containment manhole. The containmentvessel includes at least one wall that surrounds an existing pipesection operably associated with the underground fuel storage tank whenthe containment vessel is installed. The at least one wall has an innersurface and an outer surface. The containment vessel has a bottom withan opening formed therein for receiving the existing pipe section whenthe containment vessel is installed. The containment vessel furtherincludes a drain valve and a conduit for connecting the drain valve to adrain in an existing spill containment manhole. The conduit is adaptedto wrap around the existing pipe section when the conduit is installed.

Still a further embodiment of the present invention is directed to amethod of repairing an existing spill containment manhole operablyassociated with an underground fuel storage tank, the method comprisingthe steps of: (i) providing a containment vessel for containing fuelspilled during filling of the underground fuel storage tank, thecontainment vessel including at least one vertically extending wall thatwhen installed surrounds an existing pipe section operably associatedwith the underground fuel storage tank, the at least one verticallyextending wall having an inner surface and an outer surface; (ii)providing a replacement cover to replace an existing cover of theexisting spill containment manhole, the replacement cover having atleast one sealing member that engages the inner surface of the at leastone wall of the containment vessel; (iii) removing an existing cover ofan existing spill containment manhole from an existing cover rim, (iv)inserting the containment vessel into the existing spill containmentmanhole without disturbing the existing surrounding retaining structurefor retaining the existing rim cover of the existing spill containmentmanhole; and, (v) placing the replacement cover in the existing rimcover so that the annular seal engages an inner surface of the at leastone wall of the containment vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, cross-sectional, exploded view of an existing spillcontainment manhole repaired by a preferred embodiment of the presentinvention.

FIG. 2 is a fragmentary perspective view of a portion of an existingspill containment manhole with a containment vessel formed in accordancewith a preferred embodiment of the present invention inserted therein.

FIG. 3 is plan view of an existing spill containment manhole with acontainment vessel formed in accordance with a preferred embodiment ofthe present invention insert therein.

FIG. 4 is a partial, cross-sectional view of a kit for repairing anexisting spill containment manhole formed in accordance with a preferredembodiment of the present invention.

FIG. 5 is a cross-sectional view taken through lines 5-5 in FIG. 3.

FIG. 6 is a perspective view of a containment vessel formed inaccordance with a preferred embodiment of the present invention.

FIG. 7 is a plan view of the containment vessel depicted in FIG. 6.

FIG. 8 is an enlarged cross-sectional view of the upper flange of thecontainment vessel depicted in FIG. 6.

FIG. 9 is an enlarged cross-sectional view of an alternative upperflange of the containment vessel.

FIG. 10 is a cross-sectional view of a second preferred embodiment ofthe present invention depicting the containment vessel removed from theexisting spill containment manhole.

FIG. 11 is a cross-sectional view of the second preferred embodiment ofthe present invention depicting the containment vessel installed in theexisting spill containment manhole.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The most preferred forms of the invention will now be described withreference to FIGS. 1-11. The appended claims are not limited to the mostpreferred forms and no term used herein is to be given a meaning otherthan its ordinary meaning unless expressly stated otherwise. The phrase“repairing an existing spill containment manhole” shall be interpretedto include upgrading an existing spill containment manhole as well asservicing an existing spill containment manhole that is leaking orsuspected to leak in the future.

FIGS. 1 Through 9

Referring to FIGS. 1 to 3 and 5, an existing spill containment manhole Ais illustrated in one of many possible configurations. As previouslyexplained, the existing spill containment manhole A is mounted above anunderground fuel storage tank (not shown). It should be noted that theremovable cover of the existing spill containment manhole A illustratedin FIG. 1 has been removed and replaced with cover 4 formed inaccordance with a preferred embodiment of the present invention.Further, FIG. 1 illustrates containment vessel 2 formed in accordancewith a preferred embodiment of the present invention inserted into theexisting spill containment manhole A.

The existing spill containment manhole A includes a cover rim B. Thecover rim B includes a recessed portion 6 for receiving a removablecover. The cover rim B is typically retained in place by one or morelayers of concrete or asphalt. The existing spill containment manhole Afurther includes an expandable body portion C. Typically, the upper endof the expandable body portion C is clamped or otherwise secured to thecover rim B while the base D is secured to a fill port or nipple E andriser pipe coupling F. It should be noted that a removable fill cap (notshown) is typically secured to the uppermost portion of the fill port ornipple E. A riser pipe (not shown) is connected at it upper under tocoupling F and at its lower end to the underground fuel storage tank(not shown).

Referring to FIG. 5, the existing spill containment manhole A mayinclude a drain G configured to allow fuel collecting in the existingspill containment manhole A to drain back into the underground fuelstorage tank through riser pipe coupling F. Referring to FIG. 5, apassageway 8 is formed by drain D to connect the lower containmentportion of the existing spill containment manhole A to the riser pipecoupling F. It should be noted that a drain valve may be used to controlthe flow of fluid through drain D.

When the existing spill containment manhole A leaks or is suspected ofleaking in the future, containment vessel 2 may be inserted therein toisolate the existing spill containment manhole A thereby preventing fuelfrom escaping into the surrounding environment even if the existingspill containment manhole A is defective.

Referring to FIGS. 6 to 8, the containment vessel 2 preferably includesone vertically extending annular wall 10 having an inner surface 13 andan outer surface 15, a horizontally extending bottom 12 and an upperflange 14. Preferably, the containment vessel 2 is made from stainlesssteel. However, it will be readily appreciated that any suitablematerial may be used to form the containment vessel 2. As seen in FIGS.6 and 7, the containment vessel 2 preferably includes a largesubstantially circular opening 16 to allow an individual access to theinterior of the containment vessel 2. Bottom 12 includes a suitablysized opening 18 to allow the fill port or nipple E to extendtherethrough as shown in FIG. 5.

The containment vessel 2 includes a compact seal assembly H. Referringto FIGS. 1 to 5 and 6, the seal assembly H includes a seal mount orflange 20, an annular seal 22, seal retaining plate 24, and a pluralityof bolts 26. Referring to FIG. 4, the mount 20 includes a recessedannular groove 28 that receives annular seal 22. Mount 20 furtherincludes a plurality of threaded recesses for receiving bolts 26. Therecesses are formed outwardly from the annular groove 28. The annulargroove 28 may take many shapes including but not limited to square,rectangular, step-shaped, circular and semi-circular to accommodatedifferent cross-sectional configurations of the annular seal. Sealretaining plate 24 can be formed in two or more pieces each have aplurality of openings for receiving bolts 26. When seal assembly H isfully assembled, the annular seal 22 engages fill port or nipple E toisolate the lower portion of containment vessel 2 from the existingspill containment manhole A.

Referring to FIGS. 6 and 8, upper flange 14 of containment vessel 2 isannular. Upper flange 14 includes a recessed portion 30 that receivesinner annular portion 32 of cover rim B as seen in FIG. 1. As a resultof this configuration, the upper portion of the containment vessel 2extends to about grade level so as to eliminate the need for a sealantbetween an upper portion of the vessel 2 and the adjacent portion of theexisting spill containment manhole A in the containment area of eithervessel 2 or existing spill containment manhole A. This configurationalso isolates the upper portion of vessel 2 from the upper portion ofexisting spill containment manhole A. Preferably, upper flange 14includes a horizontal outwardly extending annular lip 33. Annular lip 33rests in recessed portion 6 of cover rim B. A sealant may be placedbetween lip 33 and recessed portion 6 of cover rim B.

Referring to FIG. 9, an alternative configuration for the upper flangeof vessel 2 is illustrated. Specifically, flange 34 includes a recessedportion 36 performing the same function as recessed portion 30. However,flange 34 omits an annular outwardly extending lip.

Referring to FIG. 1, replacement cover 4 includes a first annularportion 38 and a second annular portion 40. Second annular portion 40,when installed, extends into containment vessel 2. Second annularportion 40 preferably includes three annular sealing ribs 42, 44 and 46.The annular sealing ribs engage the inner surface 13 of annular wall 10of containment vessel 2 so that the repair kit including the containmentvessel 2 and cover 4 are isolated from the existing spill containmentmanhole A. When installed, replacement cover 4 is preferably at aboutgrade level.

Installation of the repair kit including the containment vessel 2 andcover 4 can be performed quickly and easily without any need to disturbthe concrete or asphalt retaining layers that retain the existing coverrim B. Specifically, installation can be readily achieved by removingthe existing fill cap cover, inserting the containment vessel 2 into theexisting spill containment manhole A, fully assembling the seal assemblyH to provide a fluid tight seal around the fill port E and positioningthe cover 4 such that the second annular portion 40 extends intocontainment vessel 2 such that ribs 42, 44 and 46 create a fluid tightseal between the replacement cover 4 and an upper portion of vessel 2.It should be noted that seal assembly H can be partially assembled priorto installation of vessel 2 in the existing spill containment manhole Asuch that only tightening of the bolts remains to be performed afterinstallation.

FIGS. 10 and 11

Referring to FIGS. 10 and 11, an alternative embodiment will now bedescribed. However, due to the similarities between this embodiment andthe previously described embodiment, only the differences will bedescribed in detail. Containment vessel 50 is similar to containmentvessel 2 with the exception of drain valve 52, drain hose 54 and drainport fitting 56. Hose 54 connects drain valve 52 to drain port fitting56. Drain port fitting 56 in turn is connected to a drain passagewayformed in the existing spill containment manhole. Like the drainpassageway 8 in the first embodiment, fuel traveling downwardly throughthe drain passageway is emptied back into the underground fuel storagetank. As seen in FIG. 11, hose 54 is configured to wrap around nipple 60and associated riser pipe coupling 62. Preferably, when drain valve 52is open fuel collected in containment vessel 50 can drain back into theunderground fuel storage tank. When vale 52 is closed, fuel collected invessel 2 will remain in vessel 2 until such time as drain valve 52 isopened.

While this invention has been described as having a preferred design, itis understood that the preferred design can be further modified oradapted following in general the principles of the invention andincluding but not limited to such departures from the present inventionas come within the known or customary practice in the art to which theinvention pertains. The claims are not limited to the preferredembodiment and have been written to preclude such a narrow constructionusing the principles of claim differentiation.

I claim:
 1. A kit for repairing an existing spill containment manholeoperably associated with an underground fuel storage tank, said kitcomprising: (a) a containment vessel for containing fuel spilled duringfilling of the underground fuel storage tank, a major portion of saidcontainment vessel being adapted to be inserted into an existing spillcontainment manhole, said containment vessel surrounding an existingpipe section operably associated with the underground fuel storage tankwhen said containment vessel is installed, said containment vesselincluding an annular wall, a bottom having an opening for receiving theexisting pipe section and a flange, said flange being disposed at theuppermost portion of said containment vessel, said annular wall havingan inner surface and an outer surface, said annular wall beingcontinuous and uninterrupted such that said annular wall is free ofjoints, said annular wall extending from said bottom to said flange;and, (b) a replacement cover to replace an existing cover of theexisting spill containment manhole, said replacement cover having afirst annular portion and a second annular portion, said second annularportion being adapted to extend into said containment vessel when saidreplacement cover is installed, said first annular portion beingdisposed above said second annular portion, said replacement coverhaving at least one sealing member that engages said inner surface ofsaid annular wall of said containment vessel when installed, said atleast one sealing member extending outwardly from said second annularportion and being disposed between said second annular portion and saidinner surface of said annular wall of said containment vessel.
 2. A kitas set forth in claim 1, wherein: (a) said sealing member is fixed tosaid removable cover such that upon removal of said removable cover saidsealing member is removed with said removable cover.
 3. A kit as setforth in claim 2, wherein: (a) said at least one sealing member includesa plurality of sealing ribs each of which extends outwardly from saidsecond annular portion of said replacement cover.
 4. A kit as set forthin claim 2, wherein: (a) a top surface of said first portion of saidreplacement cover when said replacement cover is installed is disposedat grade level.
 5. A kit as set forth in claim 1, wherein: (a) a topsurface of said first annular portion has a diameter greater than aninner diameter of an existing cover rim, the existing cover rim isretained in place by one of asphalt and concrete.
 6. A kit as set forthin claim 5, wherein: (a) said flange is annular and includes asubstantially horizontally extending lip that is received in a recessformed in the existing cover rim of an existing containment manhole whensaid containment vessel is installed.
 7. A kit as set forth in claim 6,wherein: (a) said substantially horizontally extending lip and saidannular wall are formed from a single piece of material.
 8. A kit as setforth in claim 7, wherein: (a) said substantially horizontally extendinglip surrounds an inner annular portion of the existing cover rim of theexisting spill containment manhole when said containment vessel isinstalled.
 9. A method of repairing an existing spill containmentmanhole operably associated with an underground fuel storage tank, saidmethod comprising the steps of: (a) providing a containment vessel forcontaining fuel spilled during filling of the underground fuel storagetank, said containment vessel including at least one verticallyextending wall that when installed surrounds an existing pipe sectionoperably associated with the underground fuel storage tank, said atleast one vertically extending wall having an inner surface and an outersurface, an uppermost portion of the existing pipe section beingdisposed below a lowermost portion of a cover rim of the existing spillcontainment manhole, the cover rim being retained in place by one ofconcrete and asphalt; (b) providing a replacement cover to replace anexisting cover of the existing spill containment manhole, saidreplacement cover having a first annular portion and a second annularportion, said second annular portion being disposed below said firstannular portion, said replacement cover having at least one annular sealthat engages said inner surface of said at least one wall of saidcontainment vessel and extends outwardly from an outer surface of saidsecond annular portion of said replacement cover, said at least oneannular seal being fixed to said replacement cover so that said at leastone annular seal moves with said replacement cover; (c) removing anexisting cover of an existing spill containment manhole from an existingcover rim, (d) inserting said containment vessel into the existing spillcontainment manhole through an opening formed in the cover rim of theexisting spill containment manhole without disturbing the existingsurrounding retaining structure for retaining the existing rim cover ofthe existing spill containment manhole; and, (e) placing the replacementcover in the existing rim cover so that the annular seal engages aninner surface of said at least one wall of said containment vessel. 10.A method as recited in claim 9, further including the step of: (a)performing step (d) of claim 9 such that the existing spill containmentmanhole is isolated without any sealing substance between an upperannular portion of said at least one vertically extending wall of saidcontainment vessel and an adjacent portion of the existing spillcontainment manhole.
 11. A method as recited in claim 9, wherein: (a)the existing spill containment manhole has a first volume and saidcontainment vessel has a second volume, said second volume is greaterthan half of said first volume.